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Rebuilding a NP205

white-rhino

white-rhino

Older than dirt
Joined
May 19, 2020
Member Number
154
Messages
691
Loc
Michigan but not in Detroit
I have a twin sticked Chevy 205 in my buggy. It’s been sorta clattery since I bought it. I replaced all the bearings on the rear output shaft last year and it helped a bit.
Yesterday I lost rear axle low range. It popped out of gear a couple times then flat out ground gears.

I don’t know what’s broke but I figure it’s time for a complete rebuild.

I see a variety of complete kits on line, some with OEM gaskets, some without. Looking for input on good, bad, what to do or NOT do.

Thx

Pic for attention

51684C91-AAA3-4E21-A3D9-F362687C06C4.jpeg
 
I have a parts 205 in the back, one you figure out if you need parts let me know. I've never opened it up, just grabbed it when the price was right.
 
I'd buy a used one and rebuild that before tearing the buggy down.
 
I just bought an ebay kit that claimed to have all oem parts in it. It had all the bearings, gaskets, shims, and seals plus more. I can't find the kit online now, but i can look when i get home.

Eta and by just, i mean like 3 years ago:homer:
 
The grinding could be from bad needle bearings causing the clutch gears to no longer line up.
 
Jphillips said:
The grinding could be from bad needle bearings causing the clutch gears to no longer line up.
Click to expand...
Maybe. I have not had any problems with it. Put it in low range on flat ground as I was idling up to a climb. Popped out. Tried it again and it popped out again. Third try sounded like it grenaded. Went from no issues to not working in a flash.
 
Bebop said:
I'd buy a used one and rebuild that before tearing the buggy down.
Click to expand...
Because I’m on vacation and driving, I haven’t done any research regarding twin stick conversions. Is it onlyin the shifters or internal? In other words can I convert a stock case without having to steal or buy anything new?
 
Jphillips said:
The grinding could be from bad needle bearings causing the clutch gears to no longer line up.
Click to expand...
Pulled it last night and popped the side inspection plate. All the needle bearings in the synchronizer slide fell out keeping it from lining up but I can't see anything broken. Not sure how that would happen???

I haven't gotten it apart to look closer.

I also made another mistake. I called NW Fab who supplied the doubler kit to ask if I could just split the 205 from the 203 without pulling it. They said yes. However, they failed to tell me there are a bunch of loose needle bearings and the shifter ring would fall out. No fucking way I am getting it back together while under the buggy. So now I have to pull the 203 also. It would have been better to leave them together. uggg
 
Well why the fuck did you pull the plate off the 203 and not just pull the 205 off the plate?


Bearings in the syncronizer slide? The fuck?
Theres a ball brg at the input, needle rollers where the 2 shafts meet, needle rollers to support the tail shaft at the tail housing, and a ball brg at the tail shaft output.

How big are the bearings and how many are there?

The pilot rollers are about 3/16-.180" and only like 9 or 11 rollers.
the needle rollers are under 1/8 -.125" and about 40 of them.
 
total newb said:
Well why the fuck did you pull the plate off the 203 and not just pull the 205 off the plate?
Click to expand...
Because people are fucking retarded.

I can't count the number of transfer cases I've seen for sale with a tail-housing bolted to them and the number of transmissions without one I've seen for sale.

Ditto for engines with torque converters bolted to them.
 
total newb said:
Well why the fuck did you pull the plate off the 203 and not just pull the 205 off the plate?


Bearings in the syncronizer slide? The fuck?
Theres a ball brg at the input, needle rollers where the 2 shafts meet, needle rollers to support the tail shaft at the tail housing, and a ball brg at the tail shaft output.

How big are the bearings and how many are there?

The pilot rollers are about 3/16-.180" and only like 9 or 11 rollers.
the needle rollers are under 1/8 -.125" and about 40 of them.
Click to expand...
Because............. a couple years ago I made a fixture that bolts to my trans jack and to the bottom of the adaptor plate. With that setup I can pull the whole 280 pounds by myself. If I split the 205 off the back of the adaptor, I would have more trouble muscling the loose 205.
Plus, I figured if I could just pull the 205 with the adaptor, it would save me with some of the linkage and if I needed to do a full rebuild on the bench I wouldn't have to deal with the weight of the 203.

That's the whole reason I took the effort to call NW Fab. I would have thought the guy would have shared that little tidbit with me.:flipoff:

I'm not 100% sure which needle bearings they are. When I saw the clusterfuck I was dealing with I got disgusted and went in the house.
arse_sidewards said:
Because people are fucking retarded.

I can't count the number of transfer cases I've seen for sale with a tail-housing bolted to them and the number of transmissions without one I've seen for sale.

Ditto for engines with torque converters bolted to them.
Click to expand...
I'm glad everyone is a expert instead of trying to be helpful. Read my explanation above. There was a specific reason for splitting where I did. It wasn't a case of "oh, I'll pull these bolts and see what happens". I SPECIFICALLY asked the guy if there were any snap rings or problems I would have and he said "nope, should be no problem".

I'll dive into it to figure out which bearings came out. My biggest issue I see is, if I don't find anything broken, why the bearings would have come out.
 
so i managed to put mine together wrong earlier this year and it would also pop out of gear and growl at me. i will show you some pics of what i did and hopefully you can avoid.

i forgot to put this bearing in... yep this big mother fucker i forgot...... just put the output cover on and went out. that was not the right way..

but i figured this out just riding around the yard. so not like it just happened one day.

good luck and put all the bearing back. lol

1692794682062.png


1692794725620.png
 
Maybe this will help understand my thoughts. Makes it pretty easy to pull when you are old and weak like me.

83BAB32B-8D43-41E5-81B1-8DD66F87E517.jpeg


Plus it makes for a decent work stand.

A46A9A7C-B8DA-490C-A8DC-86925182CD0C.jpeg



Still haven’t figured out where the bearings came from. They are .216 dia x .532 long.

B8AEBD29-9103-464E-9F1C-7B2C370381E6.jpeg
 
white-rhino said:
Maybe this will help understand my thoughts. Makes it pretty easy to pull when you are old and weak like me.

83BAB32B-8D43-41E5-81B1-8DD66F87E517.jpeg


Plus it makes for a decent work stand.

A46A9A7C-B8DA-490C-A8DC-86925182CD0C.jpeg



Still haven’t figured out where the bearings came from. They are .216 dia x .532 long.

B8AEBD29-9103-464E-9F1C-7B2C370381E6.jpeg
Click to expand...
Those look like the ones for the gear that rides on the output shaft. There is a double row of those. I have no idea how they would come out as there is the clutch gear on the inside and thrust washer and thick retaining washer on the outside.
 
are any of the shafts able to move around. up down or anything. them look like the ones that are double stacked, two rows
 
Yep, you are right. No idea how the came out. I had it apart last year and the shaft was pitted. JB Conversions was out of stock on their 300M shaft so I put it back together and ordered a replacement. It showed up over the winter so at leastI will get that replaced.

AB0DDF7A-E71C-4CC1-9D2C-1FD479B37077.jpeg


As far as how they fell out, nothing looked wrong but this retainer ring has a notch in it. No idea if it’s supposed to be this way.

60D4FFA3-B7EF-48A2-926D-3EFFCA62AE23.jpeg
 
There is a little pin that goes into the output shaft that lines up with that notch to keep the thrust washer from spinning.
 
So now that I know the failure and have the replacement parts, next question is best way to move forward. Do I pull the adaptor off the 205 and then install on the 203? And then reinstall the 205 onto the adaptor? With the loose needle bearings and the synchro gear on the fork, I think it will be hard to line the 203 back up onto the adaptor.

Looking for the best plan of attack to reassemble from those that have done it.
 
Non rotate pin.

white-rhino said:
Yep, you are right. No idea how the came out. I had it apart last year and the shaft was pitted. JB Conversions was out of stock on their 300M shaft so I put it back together and ordered a replacement. It showed up over the winter so at leastI will get that replaced.

AB0DDF7A-E71C-4CC1-9D2C-1FD479B37077.jpeg


As far as how they fell out, nothing looked wrong but this retainer ring has a notch in it. No idea if it’s supposed to be this way.

60D4FFA3-B7EF-48A2-926D-3EFFCA62AE23.jpeg
Click to expand...
 
I haven't done it, but I'd assemble on the bench and verify it shifts smoothly before pushing that big old beast back in its home.
 
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